Beam shaping system and scanner

ABSTRACT

An elongated laser beam optical assembly. The assembly has a laser light source that produces a laser beam. A cylindrical anamorphic lens has a planar surface at a first end and an anamorphic surface at a second end thereof, the first end receiving the laser beam from the laser light source and producing an output laser beam from the second end thereof. An aperture passes the output laser beam from the second end of the anamorphic lens to produce an elongated laser beam.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of Chinese Patent Applicationfor Utility Model No. 201620112663.7 for a Beam Shaping System andScanner filed Feb. 4, 2016 at the State Intellectual Property Office ofthe People's Republic of China. The foregoing patent application ishereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to bar code scanners and similar devices.In particular, the certain embodiments consistent with the presentinvention utilize an anamorphic lens in a beam shaping system of the barcode scanner to get an extremely elongated laser scanning beam capableof reading poor and damaged quality bar code symbols.

BACKGROUND

Poor quality bar codes and damaged bar codes such as those shown in FIG.1A and FIG. 1B are more difficult for a bar code reader to read. Thisresults in decreased throughput at the retail point of sale. Referringto FIG. 2, an effective way to improve the ability to read such barcodes is to use an elongated laser beam 10 in the cross-sectionaldirection (shown up and down) of laser beam scanning motion (left toright as shown), so as to help average out spatial noise and improve thesignal to noise (SNR) of laser scanning bar codes reading system.

A traditional arrangement for generating an elongated laser beam 10 isdepicted in FIG. 3. In this arrangement, a Visible Laser Diode (VLD) 14generates laser light. The VLD 14 is fitted within a yoke 18. The laserlight passed through a collimator lens 22 that causes the light raysfrom VLD 22 to be parallel to each other. The collimated light finallypasses through an aperture in a barrel 26 to cylindrical lens 30 toemerge as the elongated laser beam 10. This arrangement is discussed ingreater detail in U.S. Pat. No. 8,376,233 to Horn et al., which ishereby incorporated by reference. In this arrangement, in order to getan extremely elongated laser beam, a cylindrical Lens or a cylindricalfold mirror (CFM) is used in the optical path. Unfortunately, thiscontributes to the part count for the assembly and also increases thedifficulty of alignment of the optical system.

SUMMARY

Accordingly, in one aspect, the present invention embraces use of ananamorphic lens in a bar code reader device to generate an elongatedlaser beam in a simpler structure.

In an example embodiment, an elongated laser beam optical assembly has alaser light source that produces a laser beam. A cylindrical anamorphiclens is provided which has a planar surface at a first end and ananamorphic surface at a second end thereof, the first end receiving thelaser beam from the laser light source and producing an output laserbeam from the second end thereof. An aperture passes the output laserbeam from the second end of the anamorphic lens to produce an elongatedlaser beam.

In certain embodiments, a yoke holds the assembly in alignment. Incertain embodiments, the anamorphic lens is a plastic lens. In certainembodiments, the laser light source comprises a visible laser diode. Incertain embodiments, the curvature of the anamorphic end of theanamorphic lens is given by:

$z = \frac{( {{({CUX})x^{2}} + {({CUY})y^{2}}} )}{\begin{matrix}{1 + \sqrt{1 - {( {1 + {KX}} )({CUX})^{2}x^{2}} - {( {1 + {KY}} )({CUY})^{2}y^{2}}} +} \\{{{AR}\{ {{( {1 - {AP}} )x^{2}} + {( {1 + {AP}} )y^{2}}} \}^{2}} + {{BR}\{ {{( {1 - {BP}} )x^{2}} + {( {1 + {BP}} )y^{2}}} \}^{3}} +} \\{{{CR}\{ {{( {1 - {CP}} )x^{2}} + {( {1 + {CP}} )y^{2}}} \}^{4}} + {{DR}\{ {{( {1 - {DP}} )x^{2}} + {( {1 + {DP}} )y^{2}}} \}^{5}}}\end{matrix}}$

where:

z is sag of the surface parallel to the z-axis,

CUX, CUY are curvatures in x and y, respectively,

KX, KY are conic coefficients in x and y, respectively,

AR, BR, CR, DR are the rotationally symmetrical portions of the 4th,6th, 8th, and 10th order deformation from conic, and

AP, BP, CP, DP represent the non-rotationally symmetrical components ofthe 4th, 6th, 8th, and 10th order deformation from conic.

In certain embodiments, CUX=CUY, KX=KY, and AP=BP=CP=DP=0. In certainembodiments, CUX is approximately −1/2.1895, CUY is approximately−1/2.2350, and KX=KY=AR=BR=CR=DR=AP=BP=CP=DP=0. In certain embodiments,a laser drive circuit generates and delivers drive current signals tothe laser light source.

In another example embodiment, a laser scanning system has a housinghaving a light transmission window and an elongated laser beam opticalassembly that includes: a laser light source that produces a laser beam,a cylindrical anamorphic lens having a first surface at a first end andan anamorphic surface at a second end thereof, the first end receivingthe laser beam from the laser light source and producing an output laserbeam from the second end thereof, and an aperture that passes the outputlaser beam from the second end of the anamorphic lens to produce anelongated laser beam; and a laser scanning mechanism for scanning saidelongated laser beam out of said housing through said light transmissionwindow and across a scanning field defined external to said housing, inwhich a bar code symbol is present for scanning by said elongated laserscanning beam.

In certain embodiments, a laser drive circuit generates and deliversdrive current signals to the laser light source. In certain embodiments,a yoke holds the assembly in alignment. In certain embodiments, theanamorphic lens is a plastic lens. In certain embodiments, the laserlight source is a visible laser diode. In certain embodiments, thecurvature of the anamorphic end of the anamorphic lens is given by:

$z = \frac{( {{({CUX})x^{2}} + {({CUY})y^{2}}} )}{\begin{matrix}{1 + \sqrt{1 - {( {1 + {KX}} )({CUX})^{2}x^{2}} - {( {1 + {KY}} )({CUY})^{2}y^{2}}} +} \\{{{AR}\{ {{( {1 - {AP}} )x^{2}} + {( {1 + {AP}} )y^{2}}} \}^{2}} + {{BR}\{ {{( {1 - {BP}} )x^{2}} + {( {1 + {BP}} )y^{2}}} \}^{3}} +} \\{{{CR}\{ {{( {1 - {CP}} )x^{2}} + {( {1 + {CP}} )y^{2}}} \}^{4}} + {{DR}\{ {{( {1 - {DP}} )x^{2}} + {( {1 + {DP}} )y^{2}}} \}^{5}}}\end{matrix}}$

where:

z is sag of the surface parallel to the z-axis,

CUX, CUY are curvatures in x and y, respectively,

KX, KY are conic coefficients in x and y, respectively,

AR, BR, CR, DR are the rotationally symmetrical portions of the 4th,6th, 8th, and 10th order deformation from conic, and

AP, BP, CP, DP represent the non-rotationally symmetrical components ofthe 4th, 6th, 8th, and 10th order deformation from conic.

In certain embodiments, CUX=CUY, KX=KY, and AP=BP=CP=DP=0. In certainembodiments, the first surface comprises either a planar surface or ananamorphic surface.

In another example, an elongated laser beam optical assembly has a laserlight source that produces a laser beam. A cylindrical anamorphic lenshas a first surface at a first end and an anamorphic surface at a secondend thereof, the first end receiving the laser beam from the laser lightsource and producing an output laser beam from the second end thereof.An aperture passes the output laser beam from the second end of theanamorphic lens to produce an elongated laser beam.

In certain embodiments, the first surface comprises either a planarsurface or an anamorphic lens surface. In certain embodiments, a laserdrive circuit generates and delivers drive current signals to the laserlight source. In certain embodiments, a yoke holds the assembly inalignment; and where the anamorphic lens comprises a plastic lens andthe laser light source comprises a visible laser diode.

The foregoing illustrative summary, as well as other exemplaryobjectives and/or advantages of the invention, and the manner in whichthe same are accomplished, are further explained within the followingdetailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B depict examples of poor quality bar codes.

FIG. 2 depicts an elongated laser beam superimposed over a portion of abar code.

FIG. 3 shows a traditional laser shaping system using a cylindricallens.

FIG. 4 shows a laser shaping system using an anamorphic lens consistentwith certain embodiments of the present invention.

FIG. 5 depicts an anamorphic lens structure.

FIG. 6 shows the laser shaping system of FIG. 4 from a side view with Xand y directions clearly illustrated.

FIG. 7A shows a graph of a simulated beam profile generated by the beamshaping system without the anamorphic lens, while FIG. 7B shows a graphof a simulated beam profile generated by the beam shaping with theanamorphic lens.

FIG. 8A, FIG. 8B and FIG. 8C show a sequence of graphs depicting thebeam intensity distribution at 100 mm, 150 mm and 250 mm from theaperture 44 in barrel 26.

FIG. 9 shows a block diagram of a scanner system incorporating anoptical system consistent with certain embodiments.

DETAILED DESCRIPTION

The present invention embraces using an anamorphic lens in a beamshaping system of a bar code scanner (that scans any type of bar code,i.e., one dimensional, two dimensional and three dimensional bar codes)to get an extremely elongated laser scanning beam that is even capableof reading poor and damaged quality bar code symbols.

An example embodiment of the present laser beam shaping system is shownin FIG. 4 to use an anamorphic lens 40 between VLD 14 (residing in yokeassembly 18) and barrel 26 (having an aperture—not shown in this view).No collimator lens 22 and no cylindrical lens 30 are used to produce theelongated laser beam 10 from the barrel 26, thereby reducing the cost ofthe optical system. The anamorphic lens has two primary functions:

1) Collimation of the laser beam in the direction of the laser beamscanning motion; and

2) Elongation of the laser beam in cross-sectional direction of laserbeam scanning motion.

Compared with the traditional system as shown in FIG. 3, the presentlaser shaping system uses fewer components to get an extremely-elongatedlaser beam. This not only reduces cost, but also simplifies alignment ofthe system.

An example anamorphic lens has a planar surface 50 and an anamorphicsurface 54 as shown in FIG. 5. The anamorphic surface is an asphericsurface with bilateral symmetry in both X and Y. But, the anamorphicsurface does not necessarily have rotational symmetry. The surfaceformed without the additional aspheric terms is sometimes referred to asa biconic surface.

The equation for an anamorphic surface is given by:

$z = \frac{( {{({CUX})x^{2}} + {({CUY})y^{2}}} )}{\begin{matrix}{1 + \sqrt{1 - {( {1 + {KX}} )({CUX})^{2}x^{2}} - {( {1 + {KY}} )({CUY})^{2}y^{2}}} +} \\{{{AR}\{ {{( {1 - {AP}} )x^{2}} + {( {1 + {AP}} )y^{2}}} \}^{2}} + {{BR}\{ {{( {1 - {BP}} )x^{2}} + {( {1 + {BP}} )y^{2}}} \}^{3}} +} \\{{{CR}\{ {{( {1 - {CP}} )x^{2}} + {( {1 + {CP}} )y^{2}}} \}^{4}} + {{DR}\{ {{( {1 - {DP}} )x^{2}} + {( {1 + {DP}} )y^{2}}} \}^{5}}}\end{matrix}}$

where:

z is the sag of the surface parallel to the z-axis

CUX, CUY are the curvatures in x and y, respectively

KX, KY are the conic coefficients in x and y, respectively, andcorrespond to eccentricity in the same way as K for the ASP surface type(see discussion in “What You Need to Know About Conic Surfaces” on page236 of CONIC SURFACES, Code V Lens System Setup Reference Manual,Version 10.5, October 2012. This manual is hereby incorporated byreference).

AR, BR, CR, DR are the rotationally symmetrical portions of the 4th,6th, 8th, and 10th order deformation from the conic.

AP, BP, CP, DP represent the non-rotationally symmetrical components ofthe 4th, 6th, 8th, and 10th order deformation from the conic.

This reduces to the asphere (ASP) surface type when CUX=CUY, KX=KY, andAP=BP=CP=DP=0. When AP=BP=CP=DP=+1 or −1, the higher-order aspherizingis purely in y or x, respectively.

Key parameters of the lens are CUX, CUY, KX, KY, AR, BR, CR, DR, AP, BP,CP, DP, which are used to specify the anamorphic surface. The anamorphicsurface CUX=−12.1895, CUY=−1/2.2350, KX=KY=0, AR=BR=CR=DR=0,AP=BP=CP=DP=0″ is an optimal design corresponding to lens materialZeonex E48R for Beam Divergence of the VLD θ∥=12 degree and θ⊥=26.8degree. Diameter of aperture is 1.04 mm″. Other lens materials that havehigh transmission of light at the appropriate wavelength (e.g. 650 nmfor the 650 nm VLD that is used in the present example) can also be usedfor the anamorphic lens such as other plastics or glass, which may havea different refractive index. The anamorphic surface type parameters(CUX, CUY, KX, KY, AR, BR, CR, DR, AP, BP, CP, and DP) should beadjusted for the particular lens material used.

Referring to FIG. 6, an example of a lens assembly consistent with thepresent teachings is shown.

Using a plastic (for example, made of Zeonex® brand cyclo Olefin PolymerE48R from Zeon Chemicals, L.P.) an anamorphic lens can be produced witha planar surface and a anamorphic surface, and for the anamorphicsurface CUX=−1/2.1895, CUY=−1/2.2350, KX=KY=0, AR=BR=CR=DR=0,AP=BP=CP=DP=0.

The visible laser diode (VLD), yoke, anamorphic lens, and barrel may beassembled in the sequence shown in FIG. 6. In the present example, theVLD produces light at 650 nm wavelength.

The Beam Divergence of the VLD in this example is θ∥=12 degrees andθ⊥=26.8 degrees. The diameter of aperture is 1.04 mm.

The anamorphic lens may be rotated about the optical axis (z axis)within lens barrel (ab parallel to direction of the laser beam scanningmotion, cd parallel to the cross-sectional direction of laser beamscanning motion). The barrel can be adjusted within the yoke to changethe distance between VLD and anamorphic lens, to generate a laser beamthat is collimated in X-direction and elongated in Y-direction. Thiscollimated laser beam can then be used in a bar code scanning system toprovide enhancement in reading of bar codes at reduced parts count andlower cost.

Referring to FIG. 7A, it is noted that without the anamorphic lens, thebeam size in the x- and y-direction are almost equal. This means thatthe beam spot is almost rounded. With anamorphic lens, FIG. 7B showsthat the y-direction is larger than the x-direction. From z=0 to 340 mm,the beam spot is elongated in y-direction producing an extremelyelongated laser scanning beam.

Comparing FIGS. 7A and 7B, it is noted that only the beam size in they-direction is changed. The beam size in the x-direction (the directionof the scanning motion) is not changed and will not change scanningresolution. The detailed data used to produce the graphs of FIG. 7appears in the table below:

(a) 13.5% beam (b) 13.5% beam size/mm (without size/mm (with Distancefrom Anamorphic lens) Anamorphic lens) aperture z/mm X-directionY-direction X-direction Y-direction 0 0.833333 0.916667 0.8333330.916667 25 0.716667 0.766667 0.716667 0.883333 50 0.566667 0.6166670.566667 0.85 75 0.45 0.5 0.45 0.833333 100 0.366667 0.383333 0.3666670.816667 125 0.266667 0.266667 0.266667 0.8 150 0.183333 0.1666670.183333 0.8 175 0.2 0.183333 0.2 0.783333 200 0.25 0.233333 0.250.783333 225 0.3 0.283333 0.3 0.8 250 0.35 0.35 0.35 0.783333 2750.433333 0.45 0.433333 0.733333 300 0.533333 0.566667 0.516667 0.716667325 0.65 0.716667 0.633333 0.733333 350 0.766667 0.833333 0.75 0.75 3750.866667 0.95 0.866667 0.783333 400 0.966667 1.08333 0.966667 0.8 4251.06667 1.2 1.06667 0.816667 450 1.16667 1.31667 1.16667 0.816667 4751.26667 1.45 1.26667 0.7 500 1.36667 1.58333 1.36667 0.65

Referring to FIGS. 8A, 8B and 8C, it can be seen that in an example ofan optical system as disclosed herein, the resulting laser beam 10 thatis produced from the optical system has a width in the x direction ofabout 0.3 mm and a length in the y direction of about 1.0 mm at a zdistance of 100 mm; a width in the x direction of about 0.2 mm and alength in the y direction of about 0.8 mm at a z distance of 150 mm; anda width in the x direction of about 0.4 mm and a length in the ydirection of about 1.0 mm at a z distance of 250 mm.

As shown in FIG. 9, the assembly described above can be utilized in alaser scanning device. The laser scanning device uses a scanner system70 (e.g., having a rotatable scanning element such as a mirror) thatcauses the laser beam 10 to be scanned across the target bar code 74 ina scanning direction. A processor 82 controls the scanner 78 to causethe scanner to direct the laser beam 10 to the bar code 74 and toreceive and interpret the reflected light signals therefrom. The VLD 14is driven by a laser drive circuit 86 under control of processor 82 togenerate the laser light using laser system 60. When the bar code 74 isscanned, the output of the scanner 70 is provided to processor 82, whichsends the decoded bar code information to a host processor via a hostI/O interface 86 in this embodiment. In other embodiments, the hostprocessor may be utilized in conjunction with processor 82 to interpretthe bar code data.

In this arrangement, the scanning takes place through a lighttransmission window. Such a window can be provided in a scanner housingsuch that the laser beam scans for a bar code. The arrangement can forma part of a hand held bar code scanner or fixed position bar codescanner without limitation. Many variations will occur to those skilledin the art upon consideration of the present teachings.

While the present embodiment utilizes an anamorphic lens having oneplanar surface and one anamorphic surface, one planar surface and oneanamorphic surface as used is but one simple option. The plane surfacecan also be replaced by a second anamorphic surface (i.e., a doubleanamorphic surface). Two anamorphic surfaces form a different focalpower in the X-direction and y-direction, but could be designed tooperate as the lens used in the present application of production of anelongated laser beam. Many other variations will occur to those skilledin the art upon consideration of the present teachings.

To supplement the present disclosure, this application incorporatesentirely by reference the following commonly assigned patents, patentapplication publications, and patent applications:

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In the specification and/or figures, typical embodiments of theinvention have been disclosed. The present invention is not limited tosuch exemplary embodiments. The use of the term “and/or” includes anyand all combinations of one or more of the associated listed items. Thefigures are schematic representations and so are not necessarily drawnto scale. Unless otherwise noted, specific terms have been used in ageneric and descriptive sense and not for purposes of limitation.

1. An elongated laser beam optical assembly, comprising: a laser lightsource that produces a laser beam; a cylindrical anamorphic lens havinga planar surface at a first end and an anamorphic surface at a secondend thereof, the first end receiving the laser beam from the laser lightsource and producing an output laser beam from the second end thereof;and an aperture that passes the output laser beam from the second end ofthe anamorphic lens to produce an elongated laser beam.
 2. The assemblyaccording to claim 1, further comprising a yoke that holds the assemblyin alignment.
 3. The assembly according to claim 1, where the anamorphiclens comprises a plastic lens.
 4. The assembly according to claim 1,where the laser light source comprises a visible laser diode.
 5. Theassembly according to claim 1, where the curvature of the anamorphic endof the anamorphic lens is given by:$z = \frac{( {{({CUX})x^{2}} + {({CUY})y^{2}}} )}{\begin{matrix}{1 + \sqrt{1 - {( {1 + {KX}} )({CUX})^{2}x^{2}} - {( {1 + {KY}} )({CUY})^{2}y^{2}}} +} \\{{{AR}\{ {{( {1 - {AP}} )x^{2}} + {( {1 + {AP}} )y^{2}}} \}^{2}} + {{BR}\{ {{( {1 - {BP}} )x^{2}} + {( {1 + {BP}} )y^{2}}} \}^{3}} +} \\{{{CR}\{ {{( {1 - {CP}} )x^{2}} + {( {1 + {CP}} )y^{2}}} \}^{4}} + {{DR}\{ {{( {1 - {DP}} )x^{2}} + {( {1 + {DP}} )y^{2}}} \}^{5}}}\end{matrix}}$ where: z is sag of the surface parallel to the z-axis,CUX, CUY are curvatures in x and y, respectively, KX, KY are coniccoefficients in x and y, respectively, AR, BR, CR, DR are therotationally symmetrical portions of the 4th, 6th, 8th, and 10th orderdeformation from conic, and AP, BP, CP, DP represent thenon-rotationally symmetrical components of the 4th, 6th, 8th, and 10thorder deformation from conic.
 6. The assembly according to claim 5,where CUX=CUY, KX=KY, and AP=BP=CP=DP=0.
 7. The assembly according toclaim 5, where CUX is approximately −12.1895, CUY is approximately−1/2.2350, and KX=KY=AR=BR=CR=DR=AP=BP=CP=DP=0.
 8. The assemblyaccording to claim 1, further comprising a laser drive circuit forgenerating and delivering drive current signals to the laser lightsource.
 9. A laser scanning system, comprising: a housing having a lighttransmission window; an elongated laser beam optical assembly,comprising: a laser light source that produces a laser beam, acylindrical anamorphic lens having a first surface at a first end and ananamorphic surface at a second end thereof, the first end receiving thelaser beam from the laser light source and producing an output laserbeam from the second end thereof, and an aperture that passes the outputlaser beam from the second end of the anamorphic lens to produce anelongated laser beam; a laser scanning mechanism for scanning saidelongated laser beam out of said housing through said light transmissionwindow and across a scanning field defined external to said housing, inwhich a bar code symbol is present for scanning by said elongated laserscanning beam.
 10. The assembly according to claim 9, further comprisinga laser drive circuit for generating and delivering drive currentsignals to the laser light source.
 11. The system according to claim 9,further comprising a yoke that holds the assembly in alignment.
 12. Theassembly according to claim 9, where the anamorphic lens comprises aplastic lens.
 13. The assembly according to claim 9, where the laserlight source comprises a visible laser diode.
 14. The assembly accordingto claim 9, where the curvature of the anamorphic end of the anamorphiclens is given by: where: z is sag of the surface parallel to the z-axis,CUX, CUY are curvatures in x and y, respectively, KX, KY are coniccoefficients in x and y, respectively, AR, BR, CR, DR are therotationally symmetrical portions of the 4th, 6th, 8th, and 10th orderdeformation from conic, and AP, BP, CP, DP represent thenon-rotationally symmetrical components of the 4th, 6th, 8th, and 10thorder deformation from conic.
 15. The assembly according to claim 14,where CUX=CUY, KX=KY, and AP=BP=CP=DP=0.
 16. The assembly according toclaim 9, where the first surface comprises either a planar surface or ananamorphic surface.
 17. An elongated laser beam optical assembly,comprising: a laser light source that produces a laser beam; acylindrical anamorphic lens having a first surface at a first end and ananamorphic surface at a second end thereof, the first end receiving thelaser beam from the laser light source and producing an output laserbeam from the second end thereof; and an aperture that passes the outputlaser beam from the second end of the anamorphic lens to produce anelongated laser beam.
 18. The assembly according to claim 17, where thefirst surface comprises either a planar surface or an anamorphic lenssurface.
 19. The assembly according to claim 17, further comprising alaser drive circuit for generating and delivering drive current signalsto the laser light source.
 20. The assembly according to claim 17,further comprising a yoke that holds the assembly in alignment; andwhere the anamorphic lens comprises a plastic lens and the laser lightsource comprises a visible laser diode.